Multi-component lighter

ABSTRACT

The present lighter includes two basic components, a housing and a fuel cartridge. The housing may comprise multiple pieces. The fuel cartridge is easy to remove from the housing without the use of any tools. Thus, an empty fuel cartridge can quickly be replaced with a full one by the user. Replacing the fuel cartridge, rather than refilling it, prevents the user from coming into contact with lighter fuel. The housing and the fuel cartridge are each relatively inexpensive to mass produce. Thus, a worn or damaged housing may be removed from the lighter by the user and replaced with a new housing. The disposability and replaceability of the lighter components makes repairs to the lighter quick and inexpensive. All or part of the housing may also be replaced with a housing having a different outward appearance. A user can thus change the appearance of his or her lighter by changing housings, rather than having to purchase multiple lighters. The housing may include surface features, such as bosses, ribs and/or tensioning springs, to tighten a fit of the housing and prevent spontaneous separation. The surface features may also protect the appearance of the housing.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of application Ser. No. 11/505,250, filed on Aug. 15, 2006, the entire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to incendiary devices configured to ignite cigarettes, cigars and pipes.

2. Description of the Related Art

Many high-end lighters include refillable fuel reservoirs. When such a lighter is depleted of fuel it can be refilled using commercially available fuel. Unfortunately, the refueling process can sometimes be messy and dangerous. As fuel is transferred from a fuel source, such as a canister, into the lighter's fuel reservoir, some of the fuel may spill. The spilled fuel can not only stain fabrics and leave a foul smelling residue, but it is also highly flammable and could accidentally ignite causing injury or property damage.

Refillable lighters are generally constructed of durable, long-lasting materials and are intended to remain in working order for many years. These lighters also generally include a multitude of moving mechanical parts. Unfortunately, these moving parts sometimes wear out, causing the lighter to become inoperative. Some of these moving parts are very small and/or difficult to remove from the lighter. Therefore, when a lighter breaks down it can be very difficult, time consuming and expensive to replace the worn out parts and restore the lighter to working order.

SUMMARY OF THE INVENTION

In light of the above shortcomings of prior art lighters, one aspect of the present lighter is the realization that it would be beneficial to all users of refillable lighters to separate the lighter fuel from the user as much as possible. Thus, if a user could refill his or her lighter with only a very low risk that fuel might be spilled, the user would be safer and there would be less of a likelihood of fuel staining any fabrics or leaving a foul smell behind.

Another aspect of the present lighter is the realization that it would be beneficial to all users of refillable lighters to be able to replace worn out components of the lighters without the difficulty, delay and expense of repair procedures. For example, if a user could simply dispose of a worn out lighter component by quickly disassembling the lighter and replacing the worn out component with a new one, the user would be able to use his or her lighter again immediately instead of having to wait for a repair process to be completed by a professional. A do-it-yourself repair capability would also likely save the lighter user money in repair costs.

The preferred embodiments of the present multi-component lighter have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of this lighter as expressed by the claims, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description of the Preferred Embodiments”, one will understand how the features of the preferred embodiments provide advantages, which include quick disassembly and reassembly without the use of tools, disposable and replaceable parts, and interchangeable parts for changing an outward appearance of the lighter.

One embodiment of the present lighter comprises a housing including an actuating mechanism and a burner cylinder. The lighter further comprises a disposable fuel cartridge including a fuel reservoir configured to store fuel and a fuel transfer mechanism configured to transfer fuel from the reservoir. The fuel cartridge and the housing are configured to releasably engage one another such that they are easily separable. When the fuel cartridge and at least a portion of the housing are engaged, the fuel transfer mechanism is operably connected to the burner cylinder and configured to transfer fuel from the reservoir to the burner cylinder.

Another embodiment of the present lighter comprises a disposable fuel cartridge configured for use with a lighter. The fuel cartridge comprises a fuel reservoir configured to store fuel, and a fuel transfer mechanism configured to transfer fuel from the reservoir. The fuel transfer mechanism includes a stem and an outlet nozzle. The outlet nozzle is configured to attenuate a pressure and/or velocity of fuel passing through the outlet nozzle. An upper portion of the stem includes a first set of threads, and a lower portion of the outlet nozzle includes a second, complementary, set of threads. The outlet nozzle is releasably securable to the stem through engagement of the first set of threads with the second set of threads.

Another embodiment of the present lighter comprises a method of repairing a lighter. The method comprises the steps of at least partially disassembling the lighter by removing a first component of the lighter, and disposing of the first lighter component. The method further comprises the steps of replacing the first lighter component with a second lighter component, and at least partially reassembling the lighter by combining the second lighter component with the lighter. The first lighter component comprises at least two subcomponents that are operably secured to one another. The method is performed entirely by hand without the use of a tool.

Another embodiment of the present lighter comprises a method of replacing a substantially empty fuel cartridge of a lighter. The method comprises the steps of at least partially disassembling the lighter by removing the substantially empty fuel cartridge of the lighter from a housing thereof, and replacing the substantially empty fuel cartridge with a substantially full fuel cartridge. The method further comprises the step of at least partially reassembling the lighter by combining the substantially full fuel cartridge with the housing.

Another embodiment of the present lighter comprises a method of altering an outward appearance of a lighter. The method comprises the step of at least partially disassembling the lighter by removing at least a first portion of a housing thereof. The first housing portion has at least a first appearance characteristic. The method further comprises the step of replacing the first housing portion with a second housing portion. The second housing portion has at least a second appearance characteristic that differs from the first appearance characteristic. The method further comprises the step of at least partially reassembling the lighter by combining the second housing portion with the lighter.

Another embodiment of the present lighter comprises a lighter configured to ignite a cigarette, cigar or pipe. The lighter comprises an upper case including an actuating mechanism and a burner cylinder. An outer surface of the upper case includes at least one raised rib. The lighter further comprises a lower case including a cavity configured to receive the upper case. The lighter further comprises a disposable fuel cartridge including a fuel reservoir configured to store fuel and a fuel transfer mechanism configured to transfer fuel from the reservoir. The fuel cartridge and the upper case are configured to releasably engage one another such that they are easily separable under digital pressure. When the fuel cartridge and upper case are engaged, the fuel transfer mechanism is operably connected to the burner cylinder and configured to transfer fuel from the reservoir to the burner cylinder.

Another embodiment of the present lighter comprises a lighter configured to ignite a cigarette, cigar or pipe. The lighter comprises an upper case including an actuating mechanism, a burner cylinder and a tensioning spring. The lighter further comprises a lower case including a cavity configured to receive the upper case. The lighter further comprises a disposable fuel cartridge including a fuel reservoir configured to store fuel and a fuel transfer mechanism configured to transfer fuel from the reservoir. The tensioning spring is configured to apply a force to the lower case when the upper case is received within the lower case. The fuel cartridge and the upper case are configured to releasably engage one another such that they are easily separable under digital pressure. When the fuel cartridge and upper case are engaged the fuel transfer mechanism is operably connected to the burner cylinder and configured to transfer fuel from the reservoir to the burner cylinder.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the present multi-component lighter, illustrating its features, will now be discussed in detail. These embodiments depict the novel and non-obvious lighter shown in the accompanying drawings, which are for illustrative purposes only. These drawings include the following figures, in which like numerals indicate like parts:

FIG. 1 is an exploded front elevational view of one embodiment of the present multi-component lighter;

FIG. 2 is an exploded front elevational view of another embodiment of the present multi-component lighter, including a cutter;

FIG. 3 is an exploded front sectional view of the lighter of FIG. 1;

FIG. 4 is an assembled front sectional view of the lighter of FIG. 1, illustrating the lighter in an at rest configuration;

FIG. 5 is an assembled front sectional view of the lighter of FIG. 1, illustrating the lighter in an ignition configuration;

FIG. 6 is a front elevational view of an upper case and a fuel cartridge of the lighters of FIGS. 1 and 2;

FIG. 7 is an exploded front elevational view of an upper case and related components of the lighters of FIGS. 1 and 2, including an ignition button, a burner cover, a burner cylinder, an interior support member and a lever;

FIG. 8 is an exploded front elevational view of a fuel cartridge and related components of the lighters of FIGS. 1 and 2, including a fuel reservoir, a fuel transfer mechanism and an outlet nozzle lifting lever;

FIG. 9 is a top plan view of the outlet nozzle lifting lever of FIG. 8;

FIG. 10 is front elevational detail view of the outlet nozzle and stem of the fuel cartridge of FIG. 8;

FIG. 11 is a front elevational view of a lower case of the lighter of FIG. 1;

FIG. 12 is a left-side elevational view of the lower case of FIG. 12;

FIG. 13 is an assembled front elevational view of the lighter of FIG. 1, showing the lighter in an at rest configuration;

FIG. 14 is a front elevational view of the lighter of FIG. 13, illustrating an ignition button of the lighter in a depressed position and a burner cover of the lighter in an open position;

FIG. 15 is a top plan view of the lighter of FIG. 13;

FIG. 16 is a top plan view of the lighter of FIG. 14;

FIG. 17 is a bottom plan view of the lighter of FIG. 13;

FIG. 18 is an assembled front elevational view of the lighter of FIG. 2, showing the cutter in a closed position;

FIG. 19 is a front elevational view of the lighter of FIG. 18, showing the cutter in an open position;

FIG. 20 is a bottom plan view of the lighter of FIG. 18;

FIG. 21 is a bottom plan view of the lighter of FIG. 19;

FIG. 22 is an exploded front elevational view of another embodiment of the present multi-component lighter; and

FIG. 23 is a partially exploded right-side elevational view of the lighter of FIG. 22.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates one embodiment of the present multi-component lighter 30. The lighter 30 includes a fuel cartridge 32 and a housing 34. In the illustrated embodiment, the housing 34 includes an upper case 36 and a lower case 38. However, those of skill in the art will appreciate that in other embodiments the housing may comprise only a single component. For example, the fuel cartridge 32 could be integral with the lower case 38, or the upper case 36 may be used with the fuel cartridge 32 without the lower case 38.

FIG. 2 illustrates another embodiment of the present lighter 40. This embodiment is substantially identical to the embodiment of FIG. 1, and includes a fuel cartridge 32 and an upper case 36. However, the lower case 42 includes a punch cutter 44 pivotably attached thereto. The structure and function of the cutter 44 are described in greater detail below.

In each of the embodiments of FIGS. 1 and 2, the lighter 30, 40 advantageously comprises two basic components, the housing 34 and the fuel cartridge 32. In addition, in the illustrated embodiments the housing 34 comprises an upper case 36 and a lower case 38, 42. However, in certain embodiments the housing may comprise only one case.

As explained in detail below, the housing 34 and the fuel cartridge 32 may be easily assembled and disassembled by the lighter user without the need to use any tools. The user can thus easily remove one or more components of the lighter and replace that component with a new one. For example, if the fuel cartridge is empty, the user can dispose of it and replace it with a new full one. By refilling the lighter in this manner, the user never comes into contact with lighter fuel. The refilling process is thus much safer and faster and prevents fuel from staining fabrics or leaving a foul smell.

As another example, a user could replace the upper case 36 if any portion of that component were to wear out or become damaged. The upper case includes several moving parts. With a typical prior art lighter including similar moving parts, if the lighter became inoperative a user would have to purchase a new lighter or have expensive and time consuming repairs performed by a professional. With the present lighter 30, 40, if the upper case 36 (or the lower case 38 or the fuel cartridge 32) becomes inoperative or unsightly for any reason, the user can purchase a replacement component and then perform a do-it-yourself repair by discarding the damaged component and replacing it with a new one. Such a do-it-yourself repair would likely be less expensive than purchasing an entire lighter, and could likely be completed in less time than repairs performed by a professional repair facility.

With reference to FIGS. 3 and 4, the upper case 36 includes a cavity 43 that is sized and shaped to receive the fuel cartridge 32 in a sliding engagement. The lower case 38 also includes a cavity 46 that is sized and shaped to receive the fuel cartridge 32 and the upper case 36 in a sliding engagement. All three components 32, 36, 38 preferably engage one another in a friction fit, so that the components are not likely to spontaneously separate from one another. In addition, the fuel cartridge 32 may include one or more bosses and/or convexities and the upper case 36 may include one or more detents, concavities and/or apertures. In the illustrated embodiment, the fuel cartridge 32 includes two convexities 48 on a front surface thereof (FIG. 1), and the upper case 36 includes two apertures 50 in a front surface thereof. Similarly located convexities and apertures may also be provided on rear surfaces of the fuel cartridge 32 and the upper case 36. When the fuel cartridge 32 and the upper case 36 are brought together as shown in FIGS. 4 and 6, the apertures 50 receive the convexities 48. The engagement of these features further strengthens the connection between the fuel cartridge 32 and the upper case 36. If desired, one or more fastening members, such as screws (not shown), may be used to further strengthen the connection between the fuel cartridge 32 and the upper case 36. For example, a screw may extend through the upper case 36 and into the fuel cartridge 32. Preferably, however, the screw would not compromise the integrity of the fuel cartridge, which could cause fuel to leak.

With reference to FIGS. 1 and 2, the upper case 36 may also include one or more bosses 51. In the illustrated embodiment, two spaced bosses 51 are provided on a front surface of the upper case 36, near a lower edge thereof. Similarly located bosses 51 may also be provided on a rear surface of the upper case 36. The bosses 51 engage inner surfaces of the lower case 38, 42. Thus, as the upper case 36 is slid into or out of the lower case 38, 42, the front and rear surfaces of the upper case 36 are protected against scratches that could be caused by contact with inner surfaces of the lower case 38, 42. The bosses 51 thus prolong the new appearance of the upper case 36. The bosses 51 may also provide a more snug fit between the upper case 36 and the lower case 38, 42, thereby lessening the chances that these two components could spontaneously separate. And, the bosses 51 may engage detents or depressions (not shown) in the inner surfaces of the lower case 38, 42 to further secure the lower case 38, 42 and the upper case 36 to one another.

With reference to FIGS. 22 and 23, the upper case 36 may also include one or more raised ribs 53. The ribs serve similar functions as the bosses 51 illustrated in FIGS. 1 and 2. That is, they protect the surfaces of the upper case 36 and provide a more snug fit between the upper case 36 and the lower case 38, 42. In the illustrated embodiment, each rib comprises an embossed, or raised, surface that extends upward in a substantially straight vertical line from adjacent a lower end of the upper case 36. With reference to FIG. 23, upper and lower ends 55 of each rib 53 may slope toward the upper case 36. As the upper case 36 is slid into the lower case 38, the sloped surfaces 55 contact upper edges 57 of the lower case 38 and help to guide the upper case 36 into the lower case 38.

In the illustrated embodiment, three horizontally spaced and vertically oriented ribs 53 are provided on the front surface of the upper case 36. Three similarly spaced and oriented ribs may also be provided on a rear surface of the upper case 36. A further rib is provided on a left-side surface of the upper case 36. Those of ordinary skill in the art will appreciate that the ribs 53 could have other shapes and/or configurations, that fewer or more ribs could be provided, and that the ribs could be differently located. For example, the rib 53 on the left-side surface may not be provided.

With reference to FIG. 23, the upper case 36 may include a tensioning spring 59. In the illustrated embodiment, the tensioning spring comprises two oppositely extending, cantilevered leaf springs 61. The leaf springs 61 are formed from a flat plate 63 having two U-shaped voids 65. The open ends of the voids 65 face one another. A free end of each leaf spring includes a convexity 67. With reference to FIG. 22, the convexities 67 extend outward from a right-side surface of the upper case 36, thereby creating an interference fit between the upper case 36 and the lower case 38. Thus, when the upper case 36 is positioned within the lower case 38, the leaf springs 61 are bent inward by contact between the convexities 67 and the inner surface of the lower case 38. The bent leaf springs 61 thus create a tensioning force that holds the upper case 36 snugly within the lower case 38. Those of ordinary skill in the art will appreciate that the tensioning spring 59 need not be provided.

With reference to FIG. 3, the fuel cartridge 32 further includes a cantilevered spring tab 52 extending from a right-side surface thereof. An upper end of the spring tab 52 adjoins a fuel reservoir portion 54 of the fuel cartridge 32, and a cantilevered portion extends generally downwardly therefrom. Beginning near a vertical center thereof, a right side of the spring tab 52 slopes outwardly and then inwardly as a thickness of the spring tab 52 increases and then decreases toward a free end 56 of the spring tab 52. A maximum thickness of the spring tab 52 occurs at a ridge 58 on the lower half thereof. The ridge 58 and the sloped surfaces to either side of the ridge 58 engage an opening 60 on a tongue 62 of the upper case 36, as shown in FIG. 4. With reference to FIG. 3, as the fuel cartridge 32 is slid into the cavity 43 in the upper case 36, the upper sloped surface 64 on the spring tab 52 engages a lower edge 66 of the tongue 62, and the spring tab 52 flexes as the fuel cartridge 32 is slid further into the upper case 36. As the fuel cartridge 32 and the upper case 36 near the fully engaged configuration of FIG. 4, the ridge 58 passes a lower edge 68 of the opening 60 in the tongue 62 and the spring tab 52 pops outwardly as the ridge 58 pops into the opening in the tongue 62. The engagement of these features further strengthens the connection between the fuel cartridge 32 and the upper case 36.

FIG. 7 illustrates the upper case 36 and its related components. The upper case 36 comprises a rigid outer casing 70 that is shaped substantially as a rectangular parallelepiped and includes interior cavities that receive various components. In the illustrated embodiment, the upper case 36 houses an electronic piezo 72 (FIG. 3) that produces a spark to ignite the lighter fuel and produce a flame. The structure and function of a typical electronic piezo, and its related components, is well known to those of ordinary skill in the art. Accordingly, the operation of some of the components of the present lighter will not be discussed in detail. Those of ordinary skill in the art will appreciate, however, that the present lighter could include alternative apparatus for producing a spark. For example, the lighter could include a flint and a metal spark wheel.

An upper right-hand portion of the outer casing 70 receives a reciprocating ignition button 74 (FIGS. 3, 7 and 13-16). The button 74 is mounted on a spring (not shown), which is located inside a housing 76 (FIG. 3). When the lighter user depresses and releases the button 74, the spring returns the button 74 to the at rest configuration illustrated in FIG. 3. An upper left-hand portion of the outer casing 70 receives a burner cylinder 78. A lower end 80 of the burner cylinder 78 receives fuel from the fuel cartridge 32 and discharges the vaporized fuel into the atmosphere through one or more flame holes 82 (FIGS. 3 and 16) each time the ignition button 74 is depressed. A spark discharge unit 84 located adjacent the burner cylinder 78 produces a spark each time the ignition button 74 is depressed. The spark ignites the vaporized fuel to produce a flame that burns in a space just above the burner cylinder 78. Front and rear surfaces of the casing 70 may include openings 85 (FIG. 7) that enable air to pass through to the burner cylinder 78 to enhance the combustion there. However, as those of ordinary skill in the art will appreciate, the openings 85 need not be provided.

The upper left-hand portion of the outer casing 70 also receives a hinged cover 86. The cover 86 is substantially L-shaped in profile. A lower portion thereof includes an aperture 88 (FIG. 7) that receives a pin 90 (FIG. 3). The pin 90 passes through the outer casing 70 and through the aperture 88 to pivotably secure the cover 86 to the upper case 36. A lever 92 actuates the cover 86 in response to movement of the ignition button 74. With reference to FIGS. 4 and 5, the lever 92 is pivotably mounted to the upper case 36 with a pin 94 in a manner similar to the cover 86. When the lighter 30 user depresses the button 74, as shown in FIG. 5, the button 74 moves a right-hand portion of the lever 92 downward, causing the lever 92 to pivot about the pin 94, which is disposed near a left-to-right center of the lever 92. As the lever 92 pivots, a left-hand portion thereof moves upward and applies a force to the lower end of the cover 86. The applied force induces a rotation of the cover 86 about its pin 90 and moves the cover 86 to the open configuration FIG. 5. When the user releases the button 74, the spring (not shown) urges the button 74 back upward to the at rest position, as shown in FIG. 4. As the button 74 moves upward the lever 92 pivots back toward its at rest position, and the cover 86 does the same.

A right-hand portion of the outer casing 70 receives an interior support member 96 that locates and supports various components of the lighter 30. For example, with reference to FIG. 3, a right-hand portion of the support member 96 includes an elongate vertical cavity 98 that contains the piezo 72 and the housing 76 for the spring (not shown). A lower surface 100 of the support member 96 includes a female guide member in the form of a cavity 102 that receives a male guide member in the form of a prong 164 extending from the fuel cartridge 32, as explained in greater detail below. A tongue 62 extends downward from a lower right-hand corner of the support member 96 (FIG. 7). A left-side surface of the tongue 62 includes a groove 104 (FIG. 3) that receives and guides the spring tab 52 of the fuel cartridge 32, as described above. The tongue 62 also includes an opening 60 that receives the ridge 58 of the spring tab 52, as also described above.

FIG. 8 illustrates an exploded view of the fuel cartridge 32. The fuel cartridge 32 comprises a fuel reservoir 54 having an interior cavity 106 (FIG. 3) configured to store fuel in a liquid and/or gaseous phase. For example, the fuel may be butane or any other suitable fuel. In the illustrated embodiment, the fuel reservoir 54 comprises a lower portion 108 shaped substantially as a rectangular parallelepiped, and an upper portion 110 that is also shaped substantially as a rectangular parallelepiped. The fuel reservoir 54 may advantageously be made of molded plastic, so that the fuel reservoir 54 is relatively inexpensive to produce. The fuel reservoir 54 may also advantageously be made of a transparent or translucent material, so that an amount of liquid fuel contained within the fuel reservoir 54 is easily discernible through a visual inspection.

A left-hand side of the fuel cartridge 32 includes an elongate vertical cavity 112 (FIG. 3) configured to receive a fuel transfer column 114. The fuel transfer column 114, which is shown in an exploded view in FIG. 8, includes a tubular stem 116 configured to transmit fuel from the fuel reservoir 54 to the burner cylinder 78. In the illustrated embodiment, the stem 116 includes external threads 118 that engage internal threads (not shown) in the elongate vertical cavity 112 to secure the stem 116 within the cavity.

A flame height adjuster 120 is secured to a lower end of the stem 116, and a fuel outlet nozzle 122 is secured to an upper end of the stem 116. Rotation of the flame height adjuster 120 with respect to the stem 116 allows the user to adjust the flow rate of fuel through the fuel transfer column 114, thereby enabling adjustment of the size of the flame produced by the burner cylinder 78. The lower end of the stem 116 may also include a fuel inlet valve 124, as illustrated in FIG. 3. The fuel inlet valve 124 enables additional fuel to be added to the fuel reservoir 54 in a manner well-known in the art. However, since the fuel cartridge 32 is removable and replaceable, the fuel inlet valve 124 need not be provided. The components of the fuel transfer column 114 may be made of one or more metals, such as brass or steel, for example. However, those of ordinary skill in the art will appreciate that the fuel transfer column 114 could be made of any suitable materials that preferably do not corrode or deteriorate in the presence of lighter fuel.

FIG. 10 illustrates the upper end of the stem 116 and the fuel outlet nozzle 122 in detail, with the nozzle 122 being shown in cross-section. The outlet nozzle 122 is configured to attenuate a pressure and/or velocity of fuel passing through the outlet nozzle 122. The nozzle 122 is substantially cylindrical and includes a narrow opening 126 approximately midway therethrough. The upper end of the stem 116 is also substantially cylindrical and includes first and second O-rings 128. A lower portion 130 of the nozzle 122 slides over the O-rings 128 in a friction fit. The O-rings 128 abut the inner surface 132 of the lower portion 130 of the nozzle 122 to seal the lower end of the nozzle 122 and prevent the escape of fuel therethrough.

The upper end of the stem 116 further includes external threads 134 located above the O-rings 128. The inner surface 132 of the nozzle 122 includes internal threads 138 that engage the external threads 134 on the stem 116 to secure the nozzle 122 to the stem 116. The threaded engagement advantageously prevents the accidental separation of these two components. This feature is of particular advantage when the fuel cartridge 32 is removed from the housing 34 for any reason, since the nozzle 122 is relatively small, and could be misplaced. This feature is also of particular advantage where the fuel cartridge 32 is separately packaged as a replacement part for the lighter 30, 40. The securely held nozzle 122 is unlikely to be lost while the user replaces an empty fuel cartridge 32 with a full one.

In the illustrated embodiment, the nozzle 122 comprises a lower portion 130 and an upper portion 136 that are separate pieces. Those of ordinary skill in the art will appreciate that the nozzle 122 could be constructed of one unitary piece. The nozzle 122 may also include a fuel chip (not shown) that may help to attenuate the pressure and/or velocity of fuel passing through the outlet nozzle 122. Those of ordinary skill in the art will appreciate, however, that the fuel chip need not be provided.

With further reference to FIG. 8, a lever 140 is pivotably attached to an upper end of the fuel cartridge 32. The lever 140 is illustrated in front elevation in FIG. 8, and in a top plan view in FIG. 9. With reference to FIG. 8, the lever 140 includes a fulcrum 142 near a left-to-right center thereof. The fulcrum 142 comprises first and second cylindrical posts 144 (FIG. 9) that extend in opposite directions from front and rear surfaces, respectively, of the lever 140. With reference to FIG. 8, the lever 140 further includes a horizontal portion 146 extending to the left of the fulcrum 142, and a diagonal portion 148 extending up and to the right of the fulcrum 142. In top plan view (FIG. 9), the horizontal portion 146 is substantially U-shaped, including first and second spaced legs 150, and the diagonal portion 148 is substantially rectangular.

With reference to FIG. 8, an upper end of the fuel cartridge 32 includes spaced front and rear walls 152. The walls 152 comprise upward extensions of front and rear walls of the fuel reservoir 54. Only the front wall is visible in FIG. 8. Each wall 152 includes an aperture 154 that pivotably receives one of the posts 144. Each aperture 154 opens to a top edge 156 of its respective wall 152. At the opening 158, a distance between first and second sides of the opening 158 is slightly less than a diameter of either post 144. The lever 140 thus snaps onto the fuel reservoir 54 as the posts 144 slide through the narrow openings 158 and into the apertures 154. The lever 140 is likewise removable from the fuel reservoir 54 by popping the posts 144 back out of the apertures 154 through the narrow openings 158.

With reference to FIG. 10, the stem 116 includes a narrow neck portion 160 below the O-rings 128. With reference to FIGS. 3 and 4, the neck 160 seats between the legs 150 of the lever 140. When the user depresses the ignition button 74, as shown in FIG. 5, a right-hand portion 162 of the lever 92 pushes downward on the diagonal portion 148 of the lever 140. The lever 140 thus pivots about its posts 144 and the legs 150 pivot upward, drawing the upper portion of the stem 116 upward. When the upper portion of the stem 116 moves upward fuel flows from the reservoir 54, through the fuel transfer column 114 and into the burner cylinder 78.

The illustrated lever 140 is advantageously constructed of one piece. The lever 140 is thus less expensive to produce than levers made of multiple pieces. The lever 140 may also be made of molded plastic, which further reduces the cost of producing the lever 140.

With reference to FIGS. 3 and 8, upper surfaces of the fuel cartridge 32 include first and second male guide members 164. Each male guide member 164 is shaped as a prong, including a substantially cylindrical base portion extending from the fuel cartridge 32, and a substantially conical portion extending upward from the base portion and terminating in a rounded tip. Those of ordinary skill in the art will appreciate that the male guide members 164 could have other configurations. With reference to FIGS. 3 and 4, each prong 164 is configured to mate with one of first and second female guide members 102, 166 in the fuel cartridge 32. In the illustrated embodiment, the first female guide member 102 comprises a substantially cylindrical cavity, and the second female guide member 166 comprises an aperture. Those of ordinary skill in the art will appreciate that the female guide members 102, 166 could have other configurations. Moreover, the positions of the male and female guide members may be reversed partially or entirely.

With further reference to FIGS. 3 and 4, as the fuel cartridge 32 is slid into the upper case 36, the pointed tip of each prong 164 enters its respective mating female guide member 102, 166. Because the pointed tip of each prong 164 is substantially smaller in diameter than its respective female guide member 102, 166, each prong 164 is very likely to locate its respective female guide member 102, 166 even if the fuel cartridge 32 and the upper case 36 are misaligned as the two components are brought together. Once the tip of each prong 164 has properly located its female guide member 102, 166, the tapering ends of the prongs 164 help to properly align the fuel cartridge 32 with the upper case 36 as the components are slid together all the way.

In one embodiment, a method of refueling the present lighter 30, 40 comprises the step of replacing an empty, or partially empty, fuel cartridge 32 with a full one, or a partially full one. The user first removes the lower case 38, 42 and then separates the empty fuel cartridge 32 from the upper case 36. The user can then discard the disposable fuel cartridge 32 and replace it with a new one that is full of fuel. Pre-filled fuel cartridges 32 may be available at retail outlets, so that the process of refueling the present lighter 30, 40 does not require the use of a fuel source, such as a canister, or the transfer of fuel from the fuel source into the fuel reservoir. As discussed above, the process of transferring fuel from a source container into a fuel reservoir can be messy and dangerous. With the present lighter an empty fuel cartridge 32 can be replaced with a commercially available full one. The replacement process keeps the user safely separated from the flammable and foul smelling fuel, which is at all times contained inside the fuel reservoir. In one embodiment, the replacement process involves the steps of removing the fuel outlet nozzle 122 from the empty fuel cartridge 32 and securing it to the new fuel cartridge 32. Commercially available replacement fuel cartridges may not include the fuel outlet nozzle 122, which may advantageously reduce the retail price of the replacement fuel cartridge. For example, the fuel outlet nozzle 122 may contain a fuel chip and/or other small components that cause it to be relatively expensive to produce. In certain embodiments, however, commercially available replacement fuel cartridges may include the fuel outlet nozzle 122, so that the method of replacing an empty fuel cartridge may not include the steps of removing the fuel outlet nozzle 122 from the empty fuel cartridge 32 and securing it to the new fuel cartridge 32.

In another embodiment, a method of refueling the present lighter 30, 40 comprises the step of adding fuel to the fuel reservoir by transferring the fuel from a fuel source, such as a canister, into the fuel reservoir through the fuel inlet valve 124. In this embodiment, there is no need to remove the lower case 38, 42 from the lighter, although the user may need to open the door 178 on the lighter 40. The user simply positions the fuel source with respect to the fuel inlet valve 124 so that the fuel may be transferred therethrough. For example, the fuel source may include a nozzle that engages the fuel inlet valve 124 and injects fuel therethrough. Such fuel sources are well-known in the art and will not be described in detail here.

FIGS. 11 and 12 illustrate the lower case 38 of the lighter 30 of FIG. 1. In the illustrated embodiment, the lower case 38 is shaped substantially as a rectangular parallelepiped with an open top. Those of ordinary skill in the art will appreciate that the illustrated shape is merely one design choice, and that housings having different shapes are entirely within the scope of the claims herein. With reference to FIG. 11, in the illustrated embodiment a front wall 168 of the lower case 38 includes first and second air inlet openings 170 near an upper left corner thereof. Similar openings may be included on a rear wall of the lower case 38. The openings 170 are substantially oval, although any other shape could be used. When the ignition button 74 of the lighter 30 is depressed and fuel is flowing to the burner cylinder 78, air flows through the air inlets 170 to the burner cylinder 78 to enhance the combustion of the fuel. Those of ordinary skill in the art will appreciate that the air inlets 170 need not be included.

With reference to FIG. 12, in the illustrated embodiment a left side wall 172 of the lower case 38 includes a fuel viewing window 174 that enables easy viewing of a level of fuel in the fuel reservoir 54. The lighter user may thus easily discern how much fuel is left in his or her lighter 30 without disassembling the lighter 30. In the illustrated embodiment, the fuel viewing window 174 comprises an oval-shaped aperture. However, those of ordinary skill in the art will appreciate that the aperture could have any shape, such as round or elliptical. Alternatively, a fuel viewing window may not be provided.

In one embodiment the lower case 38 is constructed of a metal, such as stainless steel, chrome-plated steel or anodized aluminum. The lower case 38 may also be constructed of other suitable materials, such as high-strength plastic or ceramic. The lower case 38 may have a smooth outer surface, as shown, or it may include a surface texture or pattern. The lower case 38 may also be any of a variety of colors, and/or include a logo or emblem. In one embodiment, a first lower case having a first appearance characteristic, such as a silver color, may be quickly replaced with a second lower case having a second appearance characteristic, such as a gold color. Lower cases of different colors, textures, etc. may be sold at retail outlets so that lighter owners can customize their own lighter 30 by merely replacing one lower case with another. In this manner, a given lighter 30 may be easily and inexpensively converted to match different outfits, or to be suited for certain occasions, such as a golf outing or fishing trip, for example, all without the unnecessary expense of purchasing multiple lighters. A lighter owner simply purchases multiple lower cases to use as he or she sees fit.

With reference to FIG. 3, which illustrates the lower case 38 in cross-section, a lower surface of the lower case 38 includes an aperture 176. The aperture 176 is aligned with the fuel inlet valve 124 (FIG. 17) so that the lighter user may refill the fuel reservoir 54 without disassembling the lighter 30. In the illustrated embodiment, the aperture 176 is round and is of a sufficient depth so that the flame height adjuster 120 does not protrude from the lower surface of the lighter 30 (FIG. 4). However, those of ordinary skill in the art will appreciate that the aperture 176 could have any shape and that the flame height adjuster 120 may protrude from the lower surface of the lighter 30 or may be further recessed than as shown. Those of ordinary skill in the art will further appreciate that the lower case 38 need not include any fuel access aperture at all.

FIGS. 18-21 illustrate the lighter 40 shown in FIG. 2, which includes a hinged punch cutter 44. With reference to FIG. 19, a door 178 is hinged to a lower end of the lower case 38 with a hinge pin (not shown). In the illustrated embodiment, the hinge pin is located near a lower right corner of the lower case 38, but those of ordinary skill in the art will appreciate that the hinge pin and hinge mechanism could be located anywhere on the lower case 38.

The door 178 includes an outer surface 180, which forms an outward facing surface of the lower case 38 when the door 178 is in the closed position shown in FIG. 18, and an inner surface 182. A cylindrical punch cutter 44 extends from the inner surface 182. An edge 184 of the cutter 44 spaced from the inner surface 182 is sharpened and is configured to remove a plug of wrapper and tobacco from an end of a cigar in a manner well-known in the art. A lower end of the lower case 38 includes a recess 186 (FIG. 21) into which the cutter 44 extends when the door 178 is in the closed position shown in FIG. 18.

The door 178 may be pivotable through 180° with respect to the lower case 38 as shown, or it may be pivotable through a smaller or larger angle with respect to the lower case 38. With reference to FIG. 21, a leaf spring 188 extends substantially perpendicularly from a lower surface of the lower case 38 within the recess 186, and is located near an end of the lower case 38 opposite the hinge 190. The leaf spring 188 engages a catch 192 on the door 178 to secure the door 178 in the closed position. An end of the door 178 opposite the hinge includes a boss 194 that provides a gripping surface for the user to open the door 178. By applying light pressure on the boss 194 with his or her finger, the user can overcome the holding force of the leaf spring 188 to flip open the door 178. A lower surface of the lower case 38, which is located within the recess, may include an aperture 196 that enables access to the fuel inlet valve 124, as described above with respect to the lighter 30. Those of ordinary skill in the art will appreciate that the fuel inlet access aperture 196 need not be provided.

The present lighter 30, 40 advantageously lacks a fuel hose or other components that can be difficult to align as the lighter is assembled. Some prior art lighters include a multitude of small components, and properly arranging and aligning all of these components is a difficult process that makes it very undesirable to disassemble the lighter. With the present lighter 30, 40, by contrast, the major components can be quickly and easily aligned and slid together to complete the assembly. For example, the fuel outlet nozzle 122 and the lower end 80 of the burner cylinder 78 automatically align with one another as the fuel cartridge 32 is slid into the upper case 36. And since the fuel outlet nozzle 122 and the burner cylinder 78 are separate components, the fuel outlet nozzle 122 can be quickly and easily replaced if it is damaged.

Those of ordinary skill in the art will appreciate that the above embodiments are merely examples. Each embodiment has been described as having components having particular shapes and being located in particular areas. However, many other configurations are possible. For example, certain components may be differently shaped, may be located in different places, or may be omitted entirely. Similarly, additional components beyond those described may be included. None of the embodiments disclosed above should be interpreted as limiting the scope of the claims herein.

Scope Of The Invention

The above presents a description of the best mode contemplated for the present multi-component lighter, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this lighter. This lighter is, however, susceptible to modifications and alternate constructions from that discussed above that are fully equivalent. Consequently, this lighter is not limited to the particular embodiments disclosed. On the contrary, this lighter covers all modifications and alternate constructions coming within the spirit and scope of the lighter as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the lighter. 

1. A lighter configured to ignite a cigarette, cigar or pipe, the lighter comprising: an upper case including an actuating mechanism and a burner cylinder, an outer surface of the upper case including at least one raised rib; a lower case including a cavity configured to receive the upper case; and a disposable fuel cartridge including a fuel reservoir configured to store fuel and a fuel transfer mechanism configured to transfer fuel from the reservoir; wherein the fuel cartridge and the upper case are configured to releasably engage one another such that they are easily separable under digital pressure, and when the fuel cartridge and upper case are engaged the fuel transfer mechanism is operably connected to the burner cylinder and configured to transfer fuel from the reservoir to the burner cylinder.
 2. The lighter of claim 1, wherein the upper case includes three horizontally spaced, vertically extending ribs on a front surface thereof.
 3. The lighter of claim 1, wherein the upper case includes three horizontally spaced, vertically extending ribs on a rear surface thereof.
 4. The lighter of claim 1, wherein the upper case includes at least one vertically extending rib on a side surface thereof.
 5. The lighter of claim 1, wherein the upper case further comprises a tensioning spring configured to apply a force to the lower case when the upper case is received within the lower case.
 6. The lighter of claim 5, wherein the tensioning spring comprises first and second leaf springs.
 7. The lighter of claim 6, wherein a free end of each leaf spring includes a convexity.
 8. A lighter configured to ignite a cigarette, cigar or pipe, the lighter comprising: an upper case including an actuating mechanism, a burner cylinder and a tensioning spring; a lower case including a cavity configured to receive the upper case; and a disposable fuel cartridge including a fuel reservoir configured to store fuel and a fuel transfer mechanism configured to transfer fuel from the reservoir; wherein the tensioning spring is configured to apply a force to the lower case when the upper case is received within the lower case; and the fuel cartridge and the upper case are configured to releasably engage one another such that they are easily separable under digital pressure, and when the fuel cartridge and upper case are engaged the fuel transfer mechanism is operably connected to the burner cylinder and configured to transfer fuel from the reservoir to the burner cylinder.
 9. The lighter of claim 8, wherein the tensioning spring comprises first and second leaf springs.
 10. The lighter of claim 9, wherein a free end of each leaf spring includes a convexity.
 11. The lighter of claim 8, wherein an outer surface of the upper case includes at least one raised rib.
 12. The lighter of claim 11, wherein the upper case includes three horizontally spaced, vertically extending ribs on a front surface thereof.
 13. The lighter of claim 11, wherein the upper case includes three horizontally spaced, vertically extending ribs on a rear surface thereof.
 14. The lighter of claim 11, wherein the upper case includes at least one vertically extending rib on a side surface thereof. 